air con BMW 528i 2000 E39 Workshop Manual

Downloaded from www.Manualslib.com manuals search engine
I lnterior Trim
This repair group covers interior trim removal and installation
procedures.
- Refer to the following repair groups for additional information:
250 Gearshift Linkage
41 1 Doors (interior door panels)
@ 612 Switches
620 Instruments
640 Heating and Air Conditioning [IHKA control panel!
650 Radio
721 Airbag System (SRS)
lnterior trim repairs
lnterior trim and finish panels are clipped or screwed into
place. Many of the trim retaining clips are designed
to be used
only once. When removing trim that is held in place with clips,
it is a good idea to have spare clips on hand before beginning
the job.
WARNING-
Special precautions must be observed when servicing the
BMWSupplementai Restraint System (SRS). Serious inju-
ry may result if system service is attempted by persons un-
familiar with the BMW
SRS and its approved service
procedures. BMW
speciiies that all inspection and service
should be performed by an authorized BMW
dealer.
Before performing any work involving airbags, discon-
nect the negative
() battery cable. See 721 Airbag
System (SRS).
Airbags contain a back-uppowersupply within the SRS
control module. A
5 second discharge period should be
allowed after the battery cable has been disconnected.
CAUTION-
* When working on electrical switclies or lights, always dis-
connect the negative
(-) cable from the battery and insu-
late the cable end to prevent accidental reconnection.
a Prior to disconnecting the battery, read the battery dis-
connection cautions given in
W1 General Warnings
and Cautions.
To prevent marring the trim when working on interior
components, work with plastic prying
tools or wrap the
tips of screwdrivers and pliers with tape before prying

Downloaded from www.Manualslib.com manuals search engine
51 3-4
/Interior Trim
Carefully pry cup holder (arrow) out of console,
4 Pry air vent down to release locking clips and remove.
< Remove screws (arrows) at base of front seat armrest and
slide armrest forward to remove.
4 Remove console glove box (A).
Remove rear trim panel fasteners (B).

Downloaded from www.Manualslib.com manuals search engine
Interior Trim
The E39 dashboard assembly includes the instrument clus-
ter, passenger side
airbag, glove compartment, fuse and re-
lay panel, radio. IHKA control panel oron-board monitor (if
equipped with GPS). The dash is made up of an upper and
lower sections. The lower section must be remove before the
upper section can be removed.
Dashboard removal is a complex operation. Read the proce-
dures through before starting work.
Lower dash panel assembly, removing and
installing
- Disconnect negative (-) cable from battery and cover termi-
nal with
insulating material.
--7
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nectioncautionsgiven atthe irontin001 General Warnings
and Cautions.
- Place steering column in down and extended position.
4 Remove left side foot well panel fasteners (A and B).
< Using a plastic trim tool, gently pry left and right steering col-
umn trim panels (white arrow) to remove and release snap
clip on column boot
(black arrow).
I 1 < Remove instrument cluster trim panel fasteners (arrows).
Pull trim panel out and disconnect harnesses for light
switches.
- Remove radio volume control knob.

Downloaded from www.Manualslib.com manuals search engine
Interior ~riml
Upper dash assembly, removing and
installing
- Remove lower dash assembly. See Lower dash panel as-
sembly, removing and installing.
I I 4 Remove instrument cluster fasteners (arrows) and swing
cluster out to remove.
Disconnect wiring harnesses from instrument cluster.
4 Remove A-pillar (windshield pillar) trim on left and right sides
by prying out
HPS cover (arrow).
- Remove screws beneath covers.
- Remove passenger side airbag. See 721 Airbag System
(SRS).

Downloaded from www.Manualslib.com manuals search engine
513-12
Interior Trim
< Remove steering column trim panel by releasing clips (ar-
rows).
< Remove left side mounting fasteners (arrows).
Lilt dash panel upwards and remove through passenger
door.
- Installation is the reverse of removal.
Window and door post trim panels,
removing and installing
Windshield post trim (A pillar), removing and Installing
- On 1998 and later cars, disconnect battery negative (-) cable
I
WARNING-
On 1998 and later models, front Head Protection System
(HPS)
airbags are installed in the driver and passenger side
windshieldpost
trim (A-pillar). See 721 Airbag System
(SRS) for warnings and cautions regarding airbags.
< Remove A-p~llar trim panel fastener cap (arrow)

Downloaded from www.Manualslib.com manuals search engine
51 3-1 4
llnterior Trim
Carefully pry bottom of upper trim panel away from door post
to release clips.
Pull upper trim panel straight down (arrow) to remove.
Installation is reverse of removal.
If necessary replace defective or
broken mounting clips.
Rear window pillartrim (C-pillar), removing and installing
(models without rear
HPS airbags)
1 I
WARNING-
On 1998 and later models, rear Head Protection System
(HPS)
airbags may be installed (optional equipment) in the
driver and passenger side C-pillar area.
The procedure given
below does not cover models with rear HPS airbags. See
721 Airbag System (SRS).
4 Carefully pry interior light out of C-pillar trim panel and dis-
connect wiring harness.
Carefully pry trim panel out at top to release clips,
- Pull trim panel straight up to remove.
- lnstallation is reverse of removal.
If necessary replace defective or broken mounting clips.

Downloaded from www.Manualslib.com manuals search engine
51 5-2
/Central Locking and Anti-Theft
This section covers repair information for door, trunk and car-
go compartment locks, central locking, electronic
immob~liza-
tion (EWS) and anti-theft alarm (DWA).
€39 cars are equipped with sophisticated self-diagnostic elec-
trical systems. When experiencing malfunctions relating to
central locking. EWS or anti-theft systems, start the diagnosis
process using the
BMW service tester DIS, GT 1, MoDiC or
equivalent scan tool. An advanced diagnostic scan tool can
usually pinpoint electrical faults quickly and safely.
Additional electrical information can be found in:
610 Electrical Component Locations
ELE Electrical Wiring Diagrams
Central locking in E39 vehicles controls the door
locks, trunk
or tailgate lock and fuel filler flap lock. The control module for
the Central Body Electronics system (ZKE
Ill), lknown as the
General Module (GM
Ill), controls central locking.
ZKE
Ill manages the following central locking related func-
tions:
Central locking
* Keyless entry
Key memory
Power trunk release
Electric opening of tailgate
DWA alarm system
Diagnosis
General Module
4 The General Module (GM) (arrow) is responsible for the op-
eration of central body electronics. The GM is located behind
the glove compartment.
Based on input information, the GM uses internal transistors
to switch current flow (providing voltage or ground) through
circuits and actuators. Actuators are the final controlling de-
vices used by GM to operate or control various output func-
tions such as relays and motors.
The accompanying schematic, Central locking inputs and
outputs, illustrates the GM central locking system.

Downloaded from www.Manualslib.com manuals search engine
- -
Central Locking and ~nti-~hefil
Key Memory
Whenever one of the FZV keys is used to lock or unlock the
car, the user is identified by the GM. A maximum of four
keys
can be programmed with the Key Memoryfeature. The use of
the personalized key then triggers Car Memory functions
such as heating
I AIC (IHKA) settings or memory seat position
adjustment.
Most programming of Key Memory requires the use of
BMW
scan tools (DISplus, GT1 or MoDiC). However, features such
as
IHKA blower speed and temperature store automatically
without the use of scan tools.
Available Key Memory functions vary based on vehicle equip-
ment. The functions that can be set include:
Automatic locking after start off (vehicle speed)
Selective locking
Heating
1 AJC blower speed, heated or cooled air distribu-
tion, automatic blower setting
Trunk lid soft close (SCA)
< The optional sofl close trunk feature is called SCA. The SCA
actuator is located in the panel below the trunk lid.
1. SCA motor and actuator located behind trunk trim in
rear wall of
trunlc
2. Lower edge of trunlc seal
3. Cam in open position
4. Cam in closed position
The actuator is controlled by a load relay in the General Mod-
ule (GM). The closing cam is mounted on an eccentric that is
driven by the actuator. The cam always turns
180" in the
same direction to open or close the trunk.

Downloaded from www.Manualslib.com manuals search engine
51 5-1 6
Central Locking and Anti-Theft
DOOR HANDLES AND LOCKS
In the procedures that follow, door handle removal, door lock
cylinder removal and door latch removal are covered for the
left front door. Other doors are similar although simpler, due
to the
lack of lock cylinder.
Inside door release removal is covered in the procedure for
inner door
ane el removal. See 411 Doors.
Door handle (outer), removing and
installing
NOTE-
IfBMWspecial tools 51 3201 and51 3 203 are available, the
door handle can be removed without removing the door trim
panel or door
airbag. Use the access hole behind the rubber
sealing plug on the door edge.
- Close window on front door.
- Disconnect battery negative (-) cable.
CAUTlOG
Prior to disconnecting the batter)! read the battery discon-
nection cautions given
in 001 General Warnings and Cau-
tions.
Remove front door trim panel. See 411 Doors.
Remove door-mounted air bag. See 721
Airbag System
(SRS).
Remove rubber sealing plug (arrow) from door edge
NOTE-
In the photo below, door handle and lock cylinder carrier are
shown on the work bench for clarity.
Working inside door cavity:
- Use long thin screwdriver to release locking tab A. Push
screwdriver through hole for rubber sealing plug.
Slide locking plate
B toward front of door.
Working on outside of door, lift out lower edge of handle and
pull down to remove.
Installation is reverse of removal,
Tightening torques
Airbag to door (replace screws) 8.5 Nrn (75 in-lb)

Downloaded from www.Manualslib.com manuals search engine
Central Locking and ~nti-~heel
Door latch, removing and installing
- Close window on subject door and open all other windows.
- Disconnect battery negative (-) cable
CAUTION-
Prior to disconnecting the batterl: read the battery discon-
nection cautions given in
001 General Warnings and Cau-
tions.
- Remove door trim panel. See 411 Doors.
- Remove air bag. See 721 Airbag System (SRS).
- Remove outer door handle. See Door handle (outer), re-
moving and installing.
< Working inside door cavity, release loclting tabs (arrows)
and open protective cover.
Pull down on electrical harness connector (arrow) to re-
lease.
< Working inside door cavity, next to outside door sltin:
Disconnect door lock cylinder Bowden cable from latch as-
sembly arm
(A) and support (B).
Disconnect microswitch connector (arrow).